Midea LSBLG1120/MCFN Technical & Service Manual Download

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Flooded type water cooled screw chiller (PCB Control)

MCAC-CTSM-2012-11

Nihao su

Climate solution for green environment

Flooded Type
Water cooled screw chiller

Technical service manual

LSBLG365~LSBLG1500/MCFN

Summary of Contents for LSBLG1120/MCFN

Page 1: ...oded type water cooled screw chiller PCB Control MCAC CTSM 2012 11 1 Nihao su Climate solution for green environment Flooded Type Water cooled screw chiller Technical service manual LSBLG365 LSBLG1500 MCFN ...

Page 2: ...ors 18 5 Installation of Water Pipeline System 19 III Electrical Data 23 1 Field Wiring 23 2 Electric parameter table 26 3 Control Flow Chart 27 4 Control Screen Structures 29 5 Control Screen Operation 30 6 Introduction of Major Electric Components 42 IV Maintenance and Commissioning 44 1 Commissioning 44 2 Maintenance and Service 51 V Control 79 1 Description of Energy Adjustment 79 2 Descriptio...

Page 3: ...gle head LSBLG365 MCFN 364 LSBLG465 MCFN 465 LSBLG560 MCFN 560 LSBLG750 MCFN 750 Dual head LSBLG825 MCFN 825 LSBLG925 MCFN 924 LSBLG1120 MCFN 1120 LSBLG1230 MCFN 1230 LSBLG1500 MCFN 1500 LS BLG M C F 365 LS water chiller BLG semi hermetic compressor 365 nominal cooling capacity kW Design sequence code C R134a omit for R22 F Flooded evaporator N N Factory mode ...

Page 4: ...es heat exchange efficiency provide most cost effective reliable solutions to all valuable customers Green chiller R134a environmental friendly refrigerant Refrigerant of the Chlorine free HFC with zero ozone depletion potential Very low GWP Global Warming Potential High reliability and excellent serviceability Flooded evaporator makes cleaning inside of pipes possible and guarantees high reliabil...

Page 5: ...y and it cooperates with EXV Danfoss to throttle the high pressure liquid refrigerant from condenser to evaporator EXV which is controlled by EVD module provides high precision adjustment and perfectly matches the compressor load both full load and partial load Easy and fast installation The unit has passed full factory test before being delivered to ensure the reliable working on the site The uni...

Page 6: ...rrosive environment and high humidity should be avoided Drainage system The height of water drainage should not be higher than the base of the unit on the spot Normal operation ambient temperature 10 45 Storage and transport temperature 15 50 Applicable altitude range No more than 1000m LSBLG MCFN cooler Minimum Maximum Entering temperature at start up 9 C 22 C Leaving temperature during operation...

Page 7: ...Water flow volume m3 h 63 80 96 129 Pipe diameter mm DN125 DN125 DN150 DN150 Water pressure drop kPa 39 39 38 40 Water side working MPa 1 0 1 0 1 0 1 0 Condenser Type Shell and tube condenser Water flow m3 h 73 94 113 150 Pipe diameter mm DN125 DN125 DN150 DN150 Water pressure drop kPa 51 52 51 55 Water side working MPa 1 0 1 0 1 0 1 0 Dimension Length mm 3500 3500 3640 3640 Width mm 1400 1400 142...

Page 8: ...ume m3 h 142 159 193 212 258 Pipe diameter mm DN150 DN150 DN200 DN200 DN200 Water pressure drop kPa 73 77 71 71 73 Water side working pressure MPa 1 0 1 0 1 0 1 0 1 0 Condenser Type Shell and tube condenser Water flow m3 h 168 186 226 248 300 Pipe diameter mm DN150 DN150 DN200 DN200 DN200 Water pressure drop kPa 88 90 85 85 87 Water side working pressure MPa 1 0 1 0 1 0 1 0 1 0 Dimension Length mm...

Page 9: ... 71 4 464 1 74 2 465 5 435 7 75 4 425 5 77 5 416 6 80 9 6 450 1 76 8 443 6 79 2 430 6 82 1 7 465 0 78 0 459 4 80 0 441 8 83 1 8 482 2 79 3 470 1 81 0 455 7 84 5 9 496 6 80 2 489 6 82 4 476 2 85 3 10 514 8 81 8 504 5 83 6 490 6 86 7 11 542 7 83 4 529 2 84 9 508 7 88 1 12 564 0 85 0 550 1 86 2 528 7 89 3 13 585 9 86 7 571 5 87 4 549 2 90 7 14 608 7 88 2 593 3 88 7 570 6 92 1 15 631 9 89 9 616 6 89 9...

Page 10: ... 0 143 1 754 9 147 1 739 2 153 5 6 798 6 145 8 787 1 150 2 764 0 155 7 7 825 0 148 0 815 1 151 7 783 8 157 6 8 855 5 150 5 834 1 153 6 808 5 160 3 9 881 1 152 1 868 7 156 3 844 8 161 9 10 913 3 155 3 895 1 158 7 870 4 164 6 11 962 8 158 2 938 9 161 0 902 6 167 1 12 1000 7 161 3 976 0 163 5 938 0 169 5 13 1039 5 164 4 1013 9 165 9 974 3 172 1 14 1079 9 167 4 1052 7 168 3 1012 3 174 8 15 1019 3 170 ...

Page 11: ...03 1 1125 5 208 7 1102 1 217 8 6 1190 6 206 9 1173 4 213 2 1139 0 220 9 7 1230 0 210 0 1215 2 215 3 1168 5 223 7 8 1275 5 213 6 1243 5 218 0 1205 4 227 4 9 1313 6 215 9 1295 2 221 8 1259 5 229 7 10 1361 6 220 3 1334 6 225 1 1297 7 233 5 11 1435 4 224 5 1399 7 228 5 1345 6 237 1 12 1492 0 228 9 1455 1 232 1 1398 5 240 5 13 1549 8 233 3 1511 7 235 4 1452 6 244 2 14 1610 1 237 5 1569 5 238 8 1509 2 2...

Page 12: ...Flooded type water cooled screw chiller PCB Control MCAC CTSM 2012 11 12 7 System Schematic Diagram For single head unit LSBLG365 750 MCFN For dual head unit LSBLG820 1500 MCFN ...

Page 13: ... 3600 1500 2000 2855 1320 500 780 380 640 DN150 DN150 750 MCFN 3600 1500 2000 2855 1320 500 780 380 640 DN150 DN150 Dual heads Model A B C D E F G H J Cooling water Inlet outlet Chilled water Inlet outlet 825 MCFN 4500 1600 1900 3855 1400 470 730 430 730 DN150 DN150 925 MCFN 4500 1600 1900 3855 1400 470 730 430 730 DN150 DN150 1120 MCFN 4600 1700 2100 3855 1500 440 740 390 690 DN200 DN200 1230 MCF...

Page 14: ...nnections and tubes even piping breaking Variable chilled water flow through the heat exchanges while the compressor s are operating is not recommended The chiller control set points are based upon a constant flow and variable temperature Unit Model CHILLED WATER CONDENSER WATER MIN FLOW RATE MAX FLOW RATE MIN FLOW RATE MAX FLOW RATE SIZE m3 h GPM m3 h GPM m3 h GPM m3 h GPM LSBLG365 MCFN 44 194 82...

Page 15: ...e machine Safety is only guaranteed if these instructions are carefully followed If this is not the case there is a risk of material deterioration and injuries to personnel 1 Unit Lifting 1 When transporting the unit please make sure there is no any collision happens between the unit and other objects 2 Move the unit by placing a roller in the bottom of the unit to avoid damage 3 Choose a suitable...

Page 16: ...tle dust Height Length W i d t h Recommended clearance D Maintenance clearance F R e c o m m e n d e d c l e a r a n c e E R e c o m m e n d e d c l e a r a n c e G Recommended clearance H Front of the chiller Model Dimensions LSBLG MCFN R134a FLOODED TYPE Single head Dual heads 365 465 560 750 825 925 1120 1230 1500 D mm 600 600 600 600 600 600 600 600 600 E mm 600 600 600 600 600 600 600 600 600...

Page 17: ... Foundation Dimensions D E 500 E Evap C entre Line C ond C entre Line A A A A R ubber Pad δ 15 200X200 C hiller Leg S teel Base P late δ 10 200X150 P rovided by user Anchor B olt M 20X400 P rovided by user N ut M 20 Provided by user G asket 200 P rovided by user 100 300 4 5 150X 150 400 G rout concrete after chiller in place D 500 F B R L Front side of chiller A B D rain ditch Foundation Bolt Inst...

Page 18: ...value listed below Model Isolation pad Vibration Isolator Running Weight kg Minimum load bearing kg EA Minimum Quantity Minimum load bearing kg EA Quantity LSBLG 365 MCFN 900 4 900 4 3300 LSBLG 465 MCFN 1000 4 1000 4 3600 LSBLG 560 MCFN 1200 4 1200 4 4200 LSBLG 750 MCFN 1400 4 1400 4 4500 LSBLG 825 MCFN 1800 4 1800 4 6000 LSBLG 925 MCFN 1800 4 1800 4 6500 LSBLG 1120 MCFN 2000 4 2000 4 7300 LSBLG12...

Page 19: ...kings on the unit Generally the refrigerant pipe side of the evaporator is the chilled water outlet side 2 The chilled water pipeline system must be provided with the soft connection thermometer pressure gauge water filter electronic scale remover check valve target flow controller discharge valve drain valve stop valve expansion tank etc 3 The water system must be fitted with the water pump with ...

Page 20: ... 70 of the design flow When the water flow is satisfied the flow switch shall keep in closed state 5 The water filter must be installed before the water inlet pipeline of the unit which shall be provided with a 25 mesh screen This will aid in preventing foreign material from entering and decreasing the performance of the evaporator 6 A strainer should be placed for enough upstream to prevent cavit...

Page 21: ...e and drain pipeline and their installation places shall be far away from the elbows The pressure gauge installed shall be vertical to the water pipe and the installation of the thermometer shall ensure that its temperature probe can be inserted into the water pipe directly 14 Each low point shall be fitted with a drain connection so as to drain the remaining water in the system Before operating t...

Page 22: ...mmission the chilled water pump Observe whether the water pressure is stable Observe the pressure gauges at the pump inlet and outlet and the readings of the pressure gauges and the pressure difference between the inlet and outlet change slightly when the water pressure is stable Observe whether the operating current of the pump is within the range of rated operating current inspect whether the re...

Page 23: ... of terminals The lines and control cables shall be separately paved and equipped with protective pipes to avoid intervention of supply line in control cable 2 Power section It is required to connect the power supply cable to the control cabinet of the unit when it arrives at the jobsite The power supply cable is connected to the terminals of L1 L2 L3 N and PE and the terminals need to be fixed ag...

Page 24: ... running current A Breaker size A Recommended Wire Size 365 MCFN 106 113 136 BVR50 465 MCFN 133 143 145 BVR70 560 MCFN 162 174 209 BVR95 750 MCFN 208 224 268 BVR120 825 MCFN 253 271 163 2 2 BVR70 925 MCFN 266 286 145 2 2 BVR70 1120 MCFN 324 348 209 2 2 BVR95 1230 MCFN 359 385 231 2 2 BVR95 1500 MCFN 417 462 277 2 2 BVR120 BVR Copper core PVC insulated soft wire Domestic model Conductor material In...

Page 25: ...m2 and 0 75mm2 shield wire 24 V shall be used for control signal line 10 Attentions Read the electrical wiring principle diagram and connect the wires strictly according to the wiring terminal diagram Three core shield cable RVVP3 0 75mm2 shall be used for the connection of the temperature sensor Common two core cable RVV2 0 75mm2 shall be used for the connection of flow switch to connect to the N...

Page 26: ...uch as water pump and user electric heating must be interfaced with a relay or the PCB might be burned Other outputs can be directly connected to indicator lamps or alarms 2 Electric parameter table Power Table Model Main power Power Range Quantity of comp Rated current A Starting current A Max running current A V Hz Highest Lowest LSBLG365 MCFN 380 50 10 10 1 106 810 113 LSBLG465 MCFN 380 50 10 1...

Page 27: ...compressor protection The imbalance rate of voltage of current is usually specified by compressor manufacturers and burn down due to overheating will be resulted from long time operation under abnormal working voltage The value and replacement of a scroll compressor cannot beat those of a screw compressor There are more complaints most of which concerned with normal protection with respect to this...

Page 28: ...e replace the miniature circuit breaker and inspect the above steps 3 Moulded Case Circuit Breaker a Protective condition too heavy current of units or existence of short circuit failure of units b Results of action execution complete power fail c Processing mode inspect whether the electric control part of units and insulation of loads are normal if yes power on and start the units again and meas...

Page 29: ...mepage Mode Setting Main Page Alarm Setting Password Input Status User Parameter Setting Automatic On Off Clock Setting Note Please input the user password 58806 or user manage password 40828 to enter the white interfaces If you need to set the user parameters please input user manage password 40828 to enter the purple interfaces Screen Setting Alarm Information History Alarm Information Query Sta...

Page 30: ...ent of the unit Inspect whether the red emergency stop button on the control box is in natural state 5 1 Introduction of Control Screen Home Page 1 Power indicator yellow which is on when display is powered on it is off when powered off 2 Status indicator green which flashes at low frequency when display is normally operative otherwise it is off 3 Communication indicator red which flashes at high ...

Page 31: ...remote control timing control 3 Selection of unit operation modes including three modes PUMP COOLING HEATING i e pump mode cooling mode heating mode 4 Selection of compressor including three modes DUAL NO 1 NO 2 5 Click on PgDn to enter the next page Main Page 6 Click on BACK return to the homepage of units Note The control mode and running mode can be selected optionally in standby status while o...

Page 32: ...tatus when the current detection water temperature chilled outlet water temperature in single unit or chilled inlet water temperature in Multi units is lower than the setting temperature of unit pause The compressor start to run until the current detection temperature is higher than the setting temperature of compressor start then the unit enter Running status 4 Shutting down status the status dis...

Page 33: ...otate button with a key beside the touch screen When the units need to be maintained by the user or after sale service personnel while expecting to see parameters from the touch screen the user may rotate the button to the service point and System under maintenance please don t start up will be displayed below main page at that moment Start operation is not allowed at this moment Any action of mai...

Page 34: ...ed in subsequent sections Setting Click on in main page to enter the password page Click on the dialog box of password input an input keyboard will be popped up in the interface input user manage password 40828 then click on Enter in numeric keyboard the dialog box disappears click on ENTER to enter User Parameter Setting Page User Parameter Setting Page Password Error Page Password Error Page wil...

Page 35: ...ing water temperature the setting value in cooling mode or the current chilled leaving water temperature the setting value in heating mode Temp Adjustment Period The time interval between two temperature detections Temperature Control Range Indicating the precision of the temperature control For example the factory default setting is 2 it means when the temperature is in the range of the setting t...

Page 36: ...is used for supplying power for PCB interior time in the case of failure to engage PCB Reset of PCB interior event will be resulted from too long power fail time of PCB module without battery Automatic On Off If the automatic on off function is needed please switch to TIMED mode in control mode as shown in Picture 2 firstly then enter user parameters setting page click on button to enter the follo...

Page 37: ...ress the station number of master is set to 1 Note To start up following conditions are required Restart Delaying need to display NO if YES it indicates the delaying period has not achieved Water Temp Allow Compressor Start need to display YES if NO it indicates the current temperature is not able to meet the compressor starting condition Remaining Oil Heating Time need to display 0 if more than 0...

Page 38: ...use s remote order Remote Start or Remote Stop switch to ON and then revert to OFF rapidly Chilled Cooling Water Switch indicating that current water flow status of chilled water system OFF displayed in no water flow state otherwise ON Contactor Protection indicating that when the compressor start to run the contactor act normally OFF switch to ON All of protection switches are ON in normal except...

Page 39: ...cute alarm procedure action The unit alarm status can t be removed until all of the alarms have been eliminated and alarm shutdown process has been finished Click on button and Fault in main page disappear the unit returns to normal If the warning message is more please click on to check These in red color indicate the alarms which have not been eliminated these in white color indicate the alarms ...

Page 40: ...re Interface in English 冷冻水流故障 Chilled water flow fault 冷却水流故障 Cooling water flow fault 防冻保护 Anti freeze Protection 1 高压保护 1 High pressure protection 2 高压保护 2 High pressure protection 1 低压保护 1 Low pressure protection 1 低压保护 2 Low pressure protection 1 机内保护 1 Compressor Motor Protection 2 机内保护 2 Compressor Motor Protection 1 油位过低保护 1 Low Oil Level Protection 2 油位过低保护 2 Low Oil Level Protection 1 接触...

Page 41: ...ering water temperature protection 冷却水出水温度过高保护 High cooling entering water temperature protection 1 排气温度过高保护 1 High discharge temperature protection 2 排气温度过高保护 2 High discharge temperature protection 1 排气压力变送器故障 1 Discharge pressure failure 2 排气压力变送器故障 2 Discharge pressure failure 1 排气压力过高保护 1 High discharge pressure protection 2 排气压力过高保护 2 High discharge pressure protection 1 膨胀阀模块故障 1 EXV module...

Page 42: ... touch screen Time Relay An element necessary for achieving compressor contactor star delta switchover The time set above is defined as the star running time 3 to 6S EXV Control Module Work out the suction superheat in the running process of compressors through the temperature sensor PT1000 and the pressure sensor connected to the module and regulate the opening of EXV through the suction superhea...

Page 43: ... disturbance between circuits and increase control accuracy Intermediate Relay The intermediate relay has the major action of separating control circuit from power circuit to avoid heavy current of the latter from returning to control circuit in case of any failure and burning down PCB and other important components Miniature Circuit Breaker Control on off of circuit and also has the action of sho...

Page 44: ...ropriate safety labels At least once a year thoroughly inspect the protection devices valves If the machine operates in a corrosive environment inspect the protection devices more frequently 1 Commissioning 1 1 Electrical System Connection Inspection 1 Inspect whether power distribution capacity is compliant with the power of the unit before the first start up and whether the diameter of the selec...

Page 45: ...e inspect for all connections of the main circuit in the control cabinet and all external connections of the control circuit before power connection e g oil heater compressor electronic protection circulatory water temperature sensor target type flow switch connection water pump linked control communication line connection etc inspect the bolts of the wiring terminal for looseness Inspect whether ...

Page 46: ...following case 2 Inspect whether the value of phase loss and reversal protection is set correctly The over under voltage protection value shall be 10 of the rated voltage 1 3 Unit Parts and Inspection of Leak Points 1 The discharge line valve and suction line valve of the compressor must be fully open turn anticlockwise to open and the cores shall be tightly locked to prevent leakage of refrigeran...

Page 47: ...ould be at least above the 1 2 position And there shall be no deterioration blackness of the lubricating oil or else qualified lubricating oil shall be changed before operating the unit 6 Inspect whether the pressure sensor stop valve dry filter front rear angle valve and liquid air sampling stop valve etc are all opened When the unit stops the high and low voltages shall be almost the same After ...

Page 48: ...tor electrical actuator and sensor elements of pressure temperature etc Therefore the wiring on site for the user is very simple Only the chilled water flow switch line and chilled water pump linked control line control contact is active need to be connected For the detailed connection way please refer to the circuit wiring diagram in the operation manual for the unit The attached circuit diagram ...

Page 49: ...quid and gas of the system shall be equivalent and close to the saturation pressure corresponding to the current ambient temperature The correlation of saturation temperatures and pressures the pressures in the list are gage pressures among which the atmospheric pressure is 0 1MPa of R22 and R134a refrigerant is shown in table 1 In the pressure gauge scale taking the right figure for example the v...

Page 50: ...ect whether there is alarm for trouble of the display screen if there is the trouble must be corrected 4 Inspect the electronic expansion valve control module for alarm trouble 5 Inspect whether various temperature points displayed on the display screen are within the normal range Before the operation of the unit the showed temperatures of discharge and fin and the ambient temperature are close to...

Page 51: ...ate fire extinguishers for the system and the refrigerant type used must be within easy reach 4 Do not siphon refrigerant Avoid spilling liquid refrigerant on skin or splashing it into the eyes Use safety goggles Wash any spills from the skin with soap and water If liquid refrigerant enters the eyes immediately and abundantly flush the eyes with water and consult a doctor 5 Never let an open flame...

Page 52: ...er For copper pipe with diameter above 9 52mm larger welding torch is required to facilitate even heating of the copper pipe 6 As for vacuum pump and connection gauge pipe if the vacuum pump connection is not common for the general gauge pipe the connection transition pipe must be prepared 7 As for the refrigerant tank and connection the refrigerant tank connection must be sound and not damaged In...

Page 53: ...e phase or lack of phase of power Anti freezing protection during refrigeration Protects the key components such as evaporator condenser and water pipe etc from damage because of the expanse caused by the water becomes into ice Overload protection Protects the compressor from burn due to overload running Over current protection of compressor Protects the compressor from burn due to over current ru...

Page 54: ...atisfied the chiller can restart Leaving chilled water temperature sensor short circuit open circuit display leaving chilled water temperature fault and chiller stops according to abnormal shutdown program After the sensor reset fault on screen must be cleared manually when both temperature and time condition gets satisfied the chiller can restart Entering cooling water temperature sensor short ci...

Page 55: ...down program Reset at 10 C and fault on screen must be cleared manually when both temperature and time condition gets satisfied the chiller can restart Compressor protection module Alarm when compressor protection module trips Perform abnormal protective shutdown program immediately Fault on screen must be confirmed and cleared manually when both temperature and time condition gets satisfied the c...

Page 56: ...tection trips when compressor current set point Faulted compressor will stop immediately to abnormal protective shutdown program and other normal system will keep on running After the switch reset fault on screen must be confirmed and cleared manually when both temperature and time condition gets satisfied the chiller can restart 42 C 38 C Comp OFF Comp ON ...

Page 57: ...ng value of thermal relay too low 4 Contactor Protection The coil of contactor does not suction normally The compressor stop running immediately Reset manually on the touch screen 1 The suction of the contactor is abnormal when Y type switch to type 2 The vibration during operation cause the contact to loosen 5 Anti freeze Protection Anti freeze switch OFF The compressor stop running immediately R...

Page 58: ...nit starts to work all of the compressors in the unit can not run Reset manually on the touch screen 1 The refrigerant not enough 2 EXV failure can not work abnormally 3 The delay time of low pressure switch alarm too short 4 There is plugging in the filter 5 Some water enter the refrigerant system in evaporator 6 Poor system matching the evaporator too small or the compressor too large 7 There is...

Page 59: ...r temperature is greater than the setting value 1 The cooling tower can not work normally 2 The cooling water flow not enough 13 Chilled Entering Water Temperature Sensor Failure Chilled entering water temperature sensor is abnormal open circuit or short circuit The compressor stop running immediately Reset manually on the touch screen 1 The temperature sensor failure 2 The wiring connection is no...

Page 60: ...and then gradually reduce the threshold and increase the integration time check to make sure the under any operating conditions there was no return of liquid Valves damaged or connected incorrectly the stator The stator and the valve and disconnect the cable connection with ordinary measuring coil resistance tester Two coil resistance should be around 36 Euro Otherwise replace the stator Finally c...

Page 61: ...cillation system used in the electronic expansion valve control parameters Will set the manual control valve in the position corresponding to the average work the superheat value is no longer swing First try to reduce the scale factor 30 to 50 and then increasing the integration time by the same proportion In any case the recommended use of stable system parameters Superheat setting is too low Inc...

Page 62: ...oil resistance should be around 36 Euro Otherwise replace the stator Finally check the cable connection to connect the drive Valve can not open Started using the manual control valve fully open If the superheat value is still high check the electrical wiring and or replace the valve Control process equipment due to low and off only comes with the compressor equipment LOP protection disabled The LO...

Page 63: ...ice of Key Parts In order to do maintenance when convenient a leaky tube can be plugged until retubing can be done if damaged tubes are not too many The number of tubes plugged determines how soon the evaporator must be retubed Plugging tubes will result in loss of capacity and efficiency as well as increased pump power Failed tubes should be replaced as soon as possible Up to 10 of the total numb...

Page 64: ...Cleaning Heat Exchangers Check the chiller tightness and whether there s leak of heat exchange tubes It is necessary to do nondestructive inspection for the principal weld longitudinal and circumferential weld of evaporator condenser barrel of pressure vessel Inspect and clean cooler tubes at the end of the first operating season Tube condition in the exchanger will determine the scheduled frequen...

Page 65: ...gent 10 Warning When doing cleaning with unit stops volume of cooling tower flume can be 1 2 or 1 3 of rated value but if doing cleaning with unit is runs the volume of cooling tower flume should keep rated value Midea assumes no responsibility for pressure vessel damage resulting from untreated or improperly treated water c Precautions of chemical cleaning When doing cleaning please wear rubber g...

Page 66: ...ated using a vacuum pump with a capacity that will reduce the vacuum to at least 130Pa 1mmHg A mercury manometer or an electronic or other type of micron gauge must be connected at the farthest point from the vacuum pump For readings below 130Pa an electronic or other micron gauge must be used The triple evacuation method is recommended and is particularly helpful if the vacuum pump is unable to o...

Page 67: ...low water to circulate through the condenser and the chiller IMPORTANT When adding refrigerant to the unit circulate water through evaporator continuously to prevent freezing and possible damage to the evaporator Do not overcharge and never charge liquid into the low pressure side of system If the system is under a vacuum stand the refrigerant drum with the connection up and open the drum and brea...

Page 68: ...ts the discharge gas before being conveyed again into the oil separator and re start the cycle The oil flow is granted by the pressure difference created between the condenser and the evaporator This difference depends on the cooling water and evaporator water temperatures During the start up it is vital to establish rapidly the appropriate temperature difference by checking the right cooling wate...

Page 69: ...rated under good condition 2 Avoid the debris or swarf clogging oil filter this may caused bearings failure The oil pressure differential switch will trip when the oil pressure differential reaches the critical point default 150kPa The compressor will automatically shut down to prevent the bearings from getting damaged due to the lack of lubricating oil Caution Compressor oil is pressurized Use pr...

Page 70: ... adding or removing charge 4 Remove junction box cover of compressor to be changed Check main power leads for marked numbers If no numbers are visible on leads mark leads with appropriate numbers to match those printed on the ends of the terminal lugs This is extremely important as power leads MUST be installed on the exact terminals from which they were removed 5 Disconnect main power leads from ...

Page 71: ...tallation procedure IMPORTANT the power cable must be connected to compressor correctly as per marks on the cables Wrong connection may cause reversal rotation and serious damages 1 Leak check the compressor and refrigerant lines with nitrogen Repair any leaks found Remove nitrogen from system Evacuate compressor and refrigerant lines Refer to the Refrigerant Charging Adding Charge and Oil Chargin...

Page 72: ...er inlet outlet Refer to the electric control wiring diagram for detail connection information Thermistor replacement To Replace Thermistors RT1 RT2 RT3 RT4 RT5 or RT6 Entering Leaving chilled Water Entering Leaving cooling Water Discharge Gas Temperature Disconnect appropriate connector from the PCB controller New thermistors should be spliced to existing wiring close to the connector unless new ...

Page 73: ... compressor against overcurrent Bypass the current transducers or make any changes to the factory default set points is forbidden The configuration of the module defines the Must Trip Amps MTA at which the thermal overload relay will turn the compressor off High low pressure switch All compressors have factory installed high low pressure switches See Table 6 10 Table High low pressure switch setti...

Page 74: ...essor Board scb expansion valve board exv Energy management module emm Comfortlink compressor protection Board ccp and the navigator Red led Green led Yellow led Replacing Defective PCB Controller For Midea screw chiller it adopts special refrigeration PCB controller The program and data is written into the memory by Midea in the replacement module When ordering any replacement module specify the ...

Page 75: ...ll below 0 forced circulation of antifreeze through the water circuits is one method of avoiding freeze up 1 Take measures to prevent the shutoff valve in the water supply line from being accidentally turned on 2 If a cooling tower is used and if the water pump will be exposed to freezing temperature be sure to remove the pump drain plug and leave it out so any water that can accumulate will drain...

Page 76: ...y standing 1m from the unit Watch the vibration amplitude at all times to see whether it s within permitted Check the voltage of power supply whether it s within 10 of rated voltage at any time Visual inspection Keep the unit clean if there s rust do scaling with iron brush and cover it with antirust paint Pay attention to the oil traces sign of a refrigerant leak and water traces on pipeline Chec...

Page 77: ...ck it monthly and it should be over 1MΩ when measuring with ohmmeter of 500VDC Check the running current and compare with the rated value refer to Table 9 Check the conductibility of wire and verify whether it s intact and well connected Fasten the loose bolts Check other components such as electromagnetic contactor rotary switch auxiliary relay time relay and thermostat whether they are all norma...

Page 78: ...milar operations by the user in later maintenance and service shall also be done when the power supply is disconnected 6 The non user parameters in the touch screen of the unit and electronic expansion valve control module are forbidden to be changed The non user parameters in the touch screen of the unit and electronic expansion valve control module are directly related to the performance and rel...

Page 79: ... configured leaving or entering chilled water temperature set point Temperature sensors transfer temperature signals to PCB which will calculate the optimum time to add or subtract capacity stages Special algorithm programmed in PCB will try to maintain the Control Point at the desired set point 4 stage control 50 100 The 4 step capacity control system is made of one slider three NC solenoid valve...

Page 80: ...low oil to flow back to the low pressure side through the valve channel The piston returns to the outlet of SV3 oil passage and the slide block moves to let part refrigerant flow back to the low pressure side through bypass opening This action would reduce the discharge volume and make the compressor operating at 75 loading Full load 100 operation After the completion of startup SV1 SV2 and SV3 ar...

Page 81: ...ing the refrigeration capability 2 Description of cooling tower fan control For Midea screw chiller it adopts professional PCB controller to maintain the saturated condensing temperature to a configurable set point Cooling tower fan is controlled by cooling leaving water temperature During compressor startup and operating progress cooling tower fan is OFF when cooling leaving water temperature 23 ...

Page 82: ...remain energized for 10 min after all compressors stop due to off command in order to prevent freeze up In the event a freeze protection alarm is generated the cooler pump relay will be energized whether cooler pump control is configured ON or OFF The cooler pump relay is also energized anytime a compressor is started as well as when certain alarms are generated The cooler pump relay should be use...

Page 83: ...em requirements Possible reason of the malfunction may be wrong installation direction of the switch inadequate depth of the target broken switch or wiring looseness etc New switch must be replaced if problem is switch itself 5 Demand Limit Auto unload control function For step control unit When compressor continuously operates at chilled water temperature 12 C more than 30 mins unload to 50 regai...

Page 84: ...S3 Sensor 3 pressure S4 Sensor 4 temperature Terminal Explanation Terminal Explanation DI1 Digital input 1 Connection tLAN pLAN RS485 Modbus terminal DI2 Digital input 2 Connection pLAN RS485 Modbus terminal Connection tLAN pLAN RS485 Modbus terminal aa Service port after removal of the cover need to be connected LED 1 Green 2 yellow 3 Brown 4 white 5 sets of personal computers 6 USB tLAN converte...

Page 85: ... KPa KPa 15 164 7 375 29 748 51 1351 14 171 8 388 30 770 52 1385 13 178 9 401 31 793 53 1420 12 185 10 415 32 815 54 1455 11 193 11 429 33 839 55 1492 10 201 12 443 34 863 56 1528 9 209 13 458 35 887 57 1566 8 217 14 473 36 912 58 1604 7 225 15 488 37 937 59 1642 6 234 16 504 38 963 60 1682 5 243 17 521 39 990 61 1722 4 253 18 537 40 1017 62 1763 3 262 19 554 41 1044 63 1804 2 272 20 572 42 1072 6...

Page 86: ...d 10 Dusty places such as plastic plant Large quantity 11 Sulfurous gas in the air Ultra strong 12 Natural pollution such as damp air near the coast or insects in the field goes into cooling tower Large quantity Strong Cycle under normal temp A Capacity of condenser Capacity of pipe Capacity of container 1 3 Thickness of detergent 33 Cycle under normal temp B Capacity of flume of cooling tower Cap...

Page 87: ...33 X 35 X 5 X 4 X 32 X 34 X 6 X 3 309 311 313 315 307 1YV3 1YV2 1YV1 SB1 SB2 X 13 X 12 X 15 206 208 1SL X 41 214 1SF X 43 216 P P 1SP2 1SP1 X 45 X 44 X 46 218 220 KR 222 FR 224 ST1 X 47 X 48 226 X 1 X 2 303 X 27 X 28 301 1SV5 X 42 202 202 202 L15 N 3 F2 3 E2 1 E12 1 F12 X 14 KM1 KM2 216 218 Note The dotted area showns the field wiring ...

Page 88: ... SQ1 SQ2 X 17 X 16 X 19 230 232 RT2 RT1 RT3 RT4 228 L15 N 402 404 406 410 404 412 404 12V 220V L N V V UR2 12V 0V L15 N 1 F11 2 F11 2 F11 2 B12 2 E12 X 49 X 50 X 51 X 52 X 55 X 56 X 58 X 57 X 10 X 18 RT5 408 X 54 X 53 RT5 414 X 67 X 68 RS485 Communication Note The dotted area showns the field wiring ...

Page 89: ... water cooled screw chiller PCB Control MCAC CTSM 2012 11 89 M TC BP P I RT KA EVD FU2 L17 N1 L19 L15 N 605 603 601 607 X 61 X 60 X 59 X 62 611 613 615 617 X 66 X 65 X 64 X 63 609 2 F12 2 F12 black white red green ...

Page 90: ...1KM1 1KM3 1KM2 2TA1 2TA2 2KM1 2KM3 2KM2 2FR 1U 1V 1W 1Y 1X 1Z 2U 2V 2W 2Y 2X 2Z QF1 QF2 1KM1 2KM1 SB FU1 UR1 L11 L13 L15 103 105 24V 0V 1 G2 4 F2 1 G2 3 B7 X 33 X 34 L15 N 202 222 X 30 X 29 X 31 X 32 N 1 C11 1 E11 JTX A L1 L2 L3 L N S1 S2 M1 M2 X 33 X 34 L15 N 202 236 1 C11 1 E11 1EH 2EH EV 2 B2 2 E2 1 3 5 7 9 11 1ST1 1ST2 1ST1 1ST2 3 B7 3 B10 3 B10 232 202 3 B9 3 B9 1 G4 1 G4 1SF 2SF 101 RS485 Co...

Page 91: ...B Control MCAC CTSM 2012 11 91 1KA 2KA 1FR 2FR 1KM3 1KM1 1KM1 1KT 1KM2 1KM3 1KT 107 109 111 117 119 121 123 1KM3 1KT 1KM2 1KM2 113 115 2KM3 2KM1 2KM1 2KT 2KM2 2KM3 2KT 125 131 133 2KM3 2KT 2KM2 2KM2 127 129 1 C11 1 E11 3 F2 3 F2 L15 N 4 A5 4 A5 ...

Page 92: ...18 X 17 X 20 208 210 1SL X 55 220 1SF X 57 222 P P 1SP2 1SP1 X 59 X 58 X 60 224 226 KR 232 1FR 234 ST1 X 66 238 P P 2SP2 2SP1 X 62 X 61 X 63 228 230 2SF X 65 X 64 236 X 8 X 7 321 X 38 X 40 X 42 X 39 X 41 309 311 313 2YV1 2YV2 2YV3 X 4 X 3 307 X 1 X 2 305 X 37 303 1SV5 X 56 202 202 202 L15 N X 35 X 36 301 2SV5 4 E2 4 F2 X 19 2KM1 212 214 2KM2 1KM1 1KM2 216 218 ...

Page 93: ... 22 X 21 X 24 240 242 244 2FR 2SL X 68 246 RT2 RT1 RT3 335 2KA RT4 202 L15 N 402 404 406 410 404 412 404 12V 220V L N V V UR2 12V 0V L15 N 1 E11 3 F11 3 F11 2 B12 2 E12 X 69 X 70 X 72 X 76 X 77 X 71 X 75 X 78 X 67 X 14 X 23 RT5 408 X 73 X 74 RT6 414 X 80 X 79 RS485 Communication RT7 416 X 81 X 82 RT8 418 X 84 X 83 ...

Page 94: ...M TC 1BP P I 2BP P I 1RT 2RT 1KA 2KA 1EVD 2EVD FU2 L17 N1 L19 L15 N 605 603 601 607 X 87 X 86 X 85 X 88 X 95 X 94 X 93 X 96 623 621 619 625 611 613 615 617 629 631 633 635 X 92 X 91 X 90 X 89 X 100 X 99 X 98 X 97 627 609 2 B12 2 E12 black white red green black white red green ...

Page 95: ...looded type water cooled screw chiller PCB Control MCAC CTSM 2012 11 95 Appendix 4 Explosive View Take LSBLG465 MCFN for example Unit Name Flooded Type Water cooled screw chiller Unit Model LSBLG465 MCFN ...

Page 96: ... Shim φ70 φ50 1 4 4 节流孔板 Orifice plate 1 4 5 直通球阀 DN40 Ball valve DN40 1 201601601333 4 6 电子膨胀阀 ETS100 Electronic Expansion valve body 1 201601300035 电子膨胀阀电源线 Electronic Expansion valve power line 1 5 引射回油管路 Oil Return Injecting pipe assembly 1 201690204144 5 1 文丘里管 Venturi tube 1 5 2 视液镜 DN10 Sight glass DN10 1 201800300003 5 3 过滤器 SR 070 Filter SR 070 1 201601100151 6 油分回油管路 Oil Return pipe assm...

Page 97: ...Flooded type water cooled screw chiller PCB Control MCAC CTSM 2012 11 97 ...

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